An Improved Swarm 3D Printing Platform

Abstract

A system that uses autonomous robots for 3D manufacturing an object where the robots have different tool heads for performing different manufacturing operations.

Claims

1. A system that uses mobile robots for manufacturing of 3D objects comprising: a plurality of robots having a tool head and said tool heads perform different manufacturing operations.

2. The system of claim 1 wherein at least one of said tool heads is for depositing a material.

3. The system of claim 1 wherein at least one of said tool heads picks and places an object.

4. The system of claim 1 wherein at least two tool heads print different materials.

5. The system of claim 1 including a floor and one or more of said robots include at least one battery.

6. The system of claim 5 wherein said floor is adapted to recharge said at least one battery.

7. The system of claim 5 wherein said floor further includes mounting holes, said mounting holes adapted to power said robots.

8. The system of claim 7 wherein said batteries are used for wheel movement and said floor charges said at least one battery and powers said robots when said robots are engaged with said mounting holes.

9. The system of claim 8 further including a server, said server adapted to direct said robots to a predefined printing location and then engage said mounting holes.

10. The system of claim 9 wherein said server directs a plurality of robots to print separate sections of the object.

11. The system of claim 9 wherein said server directs a plurality of robots to print separate sections of the object simultaneously.

12. A method for using mobile robots for 3D manufacturing an object comprising the steps of: providing a digital model of the object that's to be manufactured providing a plurality of robots having a tool head and at least two tool heads perform a different manufacturing operation; and a server, said server divides the said digital model into smaller sections and directs a plurality of robots to print separate sections of the object without conflicts.

13. The method of claim 12 wherein said server directs a plurality of robots to print at least two sections of the object simultaneously.

14. The method of claim 13 wherein said simultaneously printed sections are spaced apart.

15. The method of claim 12 wherein said server directs at least one robot to print a center section of the object that includes at least two spaced-apart sides, said sides have positive slopes.

16. The method of claim 15 wherein said server directs two or more robots to print spaced apart sections, said sections include spaced-apart sides having at least one negative slope and at least one positive slope.

17. The method of claim 15 wherein said server directs two or more robots to print sections adjected to said center section, said adjacent sections include spaced-apart sides having and at least one positive slope.

18. The method of claim 17 wherein at least one negative slope side of said adjacent section is joined to said positive slope side of said center section.

19. The method of claim 12 wherein said server directs two or more robots to print a series of sections, said sections include spaced-apart sides having at least one negative slope and at least one positive slope; and said negative slope side of one section is joined to a positive slope side of another section.

20. The method of claim 19 further including an overlap where said negative slope side of one section is joined to a positive slope side of another section.

21. The system of claim 1 wherein at least one of said tool heads is used is mounted on a robotic arm.

22. The system of claim 1 wherein at least one of said tool heads is not directly mounted on a robot but is carried by a Selective Compliance Assembly Robot Arm (SCARA) or other types of robotic arms.

23. The method of claim 12 wherein the printing and translational movement of said robots do not take place simultaneously, but rather, a robot moves to a predefined printing location first, then mounts to said floor through mounting holes before printing.

24. The system of claim 8 wherein said robots use batteries for wheel movement and said floor tiles charge the battery and power the printer during the printing process through mounting holes, which will also power the heated print bed tiles mounted on the floor if needed (e.g. for printing ABS).

25. The system of claim 1 wherein the mobile robots are configured to navigate on floor tile or a printing surface, said printing surface may include one or more mounting holes and power sources as well as navigation lines.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0021] In the drawings, which are not necessarily drawn to scale, like numerals may describe substantially similar components throughout the several views. Like numerals having different letter suffixes may represent different instances of substantially similar components. The drawings illustrate generally, by way of example, but not by way of limitation, a detailed description of certain embodiments discussed in the present document.

[0022] FIG. 1 shows a printing system including a platform with floor tiles, each with mounting locations for an embodiment of the present invention.

[0023] FIG. 2 shows a printing system including a mobile platform for an embodiment of the present invention.

[0024] FIG. 3 shows a chunk-based 3D printing method wherein a digital model is first split into chunks with each chunk sliced into layers and assigned to different robots for an embodiment of the present invention.

[0025] FIG. 4 depicts the tensile strength (MPa) of specimens printed with various combinations of chunk-based parameters (solid fill) along with tensile strength of standard 3D printed reference part (pattern fill) for embodiments of the present invention.

[0026] FIG. 5A shows chunks and one possible printing sequence of a large rectangular block (top view) for an embodiment of the present invention.

[0027] FIG. 5B is a dependency tree that describes the dependency relationship between the chunks, which instructs how the available robots should execute the printing process in sequence to avoid collisions for an embodiment of the present invention.

[0028] FIGS. 5C, 5D, 5E, 5F, 5G and 5H are illustrations of the cooperative 3D printing process based on the dependency tree using a simulator for an embodiment of the present invention.

[0029] FIG. 6 Illustration of chunk's dimension and printing limitations on the slope

[0030] FIGS. 7A, 7B, 7C and 7D show an iterative chunking, for an embodiment of the present invention, where planes L and R are reused and shifted to split further chunks on the left and right of the center chunk: (a) center chunk; (b) shifted plane R to the right by one chunk; (c) shifted plane R to all the right chunks; (d) shifted plane L to all the left chunks.

[0031] FIG. 8A is a top view showing a chunk overlapping of zero for an embodiment of the present invention.

[0032] FIG. 8B is a top view showing a chunk overlapping of 0.3 mm for an embodiment of the present invention.

[0033] FIG. 8C is a side view showing a chunk overlapping of 0.3 mm for an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0034] Detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed method, structure or system. Further, the terms and phrases used herein are not intended to be limiting, but rather to provide an understandable description of the invention.

[0035] In a preferred embodiment, the present invention provides two parts, a hardware platform and software. The hardware platform may be comprised of three parts: a SCARA or robotic arm 3D printer that can print based on digital models; a mobile platform to carry the robotic arm, navigate between different floor tiles, mount; and unmount the robotic arm on the floor tiles.

[0036] In a preferred embodiment, as shown in FIG. 1, the present invention includes a printing system 100 comprised of a plurality of mobile robotic printers 110A-110C and 120 for creating printed object 105 which is located on printbed 106. The print bed 106 is mounted on the floor or printing surface 130 through mounting holes 140, which may provide power to the printed when necessary. The robotic printers may include one or more robots 110A-11C having printheads 112A-112C located on robotic arms 114A-114C as well as one or more mobile gripper robots 120 having gripper mechanisms 122 located on a robotic arm 124.

[0037] The robots are configured to navigate on the floor tile or printing surface 130. The printing surface may include one or more mounting holes and power sources 140 as well as navigation lines 150. The mounting holes have self-centering features (e.g., a conical-shape) to assist in locating the mounting holes and positioning the mobile robots.

[0038] A modularized floor tile system may serve as a fixed base for the robotic arm printer. The system may also be used to power the printer and charge equipment batteries during the printing process. The system may also power the print bed when necessary.

[0039] As shown in FIG. 2, in another embodiment, system 200 may include a guided mobile platform 210 for navigation and for calibration of the robot positions. Platform 200 may have mounted thereon one or more SCARA or robotic arm 3D printer printing units 220 and 222. The units on platform 200 are adapted to work cooperatively with one or more mobile robots 230.

[0040] A gear-pump based extrusion head for printing liquid resins or hot-melt materials, such as gels, which cannot normally be printed by an FDM printhead may also be provided. Lastly, a printhead for dispensing tape-form materials (e.g., carbon fiber tape, fiberglass tape, copper tape) may be used.

[0041] In other preferred embodiments, the present invention provides a system having a hardware platform that consists of a crew of different mobile manufacturing robots and a factory floor on which manufacturing takes place. Due to the versatility of 3D printing and the importance of pick-and-place robots for assembly of pre-manufactured components, the present invention provides a printing system that may include different kinds of mobile robots such as mobile 3D printers and mobile grippers as discussed above.

[0042] In other embodiments, each mobile robot consists of an omnidirectional mobile platform that may be equipped with Mecanum wheels (or other types of omnidirectional wheels), a robotic arm such as a Selective Compliance Assembly Robot Arm, and an end effector which may include a filament extruder or gripper among other things.

[0043] Floor 130 is discretized into modularized floor tiles 160-165. The positions of the mobile platforms or robots are assisted by the navigation lines 150 and positioning sensors on the mobile platform or robot.

[0044] The robots or mobile platforms move between pre-defined locations marked by the mounting holes under battery power. For additional power requirements, a robot mounts and locks to the floor through the mounting holes, which provides stability and power for manufacturing operations.

[0045] Because the robotic arms can access its neighboring floor tiles and the robot can move to different tiles, the end effectors, such as a filament extruder, can access the entire floor space without restrictions. The robots and mobile platforms are programmed to cooperate with each other since they need to be able to align in both space and time. The spatial alignment is ensured by a positioning mechanism embedded in the robot sensors and the floor design, which can achieve less than 100 um positioning accuracy. The temporal alignment is achieved by a communication protocol designed using a pair of custom-designed commands: “WAIT” and “NOTIFY”.

[0046] A robot or mobile platform can be paused by the “WAIT” command and resumed by the “NOTIFY” command when certain required conditions are satisfied. The robots and mobile platforms communicate with each other through a wireless network, which allows different robots or mobile platforms to sync for cooperation by issuing “WAIT” and “NOTIFY” commands to specified robots.

[0047] Other software that may be used with the present invention consists of a chunk-based slicer, a scheduler, and a user interface. The chunk-based slicer divides the digital model into smaller logical manufacturing tasks that can be accomplished by individual mobile robots. The chunk-based slicer may also be configured to enable printing of objects with multiple colors and multiple materials, and with embedded pre-manufactured components.

[0048] A scheduler assigns the divided tasks to available robots and coordinates the manufacturing process to make sure no collision occurs. The scheduler may also be configured to coordinate a heterogeneous swarm of robots to work together without conflict. A user interface allows the user to interact with each available robot and the robots to communicate with each other.

[0049] In yet other aspects, the present invention uses machine learning for improving printing. One or more robots may also be configured to enable carrying live cameras and sensors to gather real-time printing information, which will be mined with machine learning algorithms to improve printing quality and cooperation among robots, i.e., make the swarm of robots smarter.

[0050] In other embodiments, the robots of the present invention are designed to be fully controllable with a set of G-code commands (i.e., every basic motor, sensor, or other operations has a corresponding G-code command) and the software translates digital models into G-code commands to be executed by the robots, which make it possible to fix issues or upgrade the system with over-the-air (OTA) software update.

[0051] To enable swarm manufacturing, two elements are provided: 1) a discretization method that can optimally divide the continuous manufacturing job into small discrete tasks under constraints; 2) a method for scheduling and coordinating the robots to work together without conflicts.

[0052] The traditional approach of 3D printing layer by layer does not work for swarm 3D printing because the previously printed layers would block the moving paths of the robots for printing the following layers. To overcome this challenge, the present invention provides a chunk-based 3D printing method that first divides the digital model into smaller chunks and slices each chunk into layers to generate G-code for printing, as illustrated in FIG. 3. A first step 300 involves inputting a design into a processor. Subsequent step 310 splits the design into chunks and step 320 slices the chunks.

[0053] For a filament extrusion-based process, the chunks are generated with a sloped angle that allows the printhead to print on top of the sloped interface of the already printed chunks, which enables the chunks to bond together during the printing process. The chunks are assigned to different robots and each chunk is printed layer by layer, which keeps the printing process localized and avoids common issues encountered in large-scale 3D printing, such as large temperature gradient across layers during the printing process and the requirement of large layer thickness due to the leveling errors in Z direction over large areas.

[0054] The results shown in FIG. 4 show that the strength of the chunk-based 3D printed part can be made at least as strong as the standard 3D printed part with an appropriate selection of the chunking parameters. MicroCT scans show that the density at the chunk-bond of the stronger parts is higher than the rest of the part. The results suggest that chunk-based 3D printing is a viable method for discretizing the continuous 3D printing process into smaller 3D printing tasks.

[0055] To enable many robots to work together, the present invention provides a method to schedule the robots to print cooperatively without colliding into each other or the printed materials as shown in FIGS. 5A-5C and 6A-6F. Based on the geometry of the chunks generated by the chunker, a dependency relationship between the chunks based on the geometric constraints between the robots, the printheads, and the chunks (i.e., one chunk can only be printed after its parent chunks are finished) is developed. A directed dependency tree (DDT) was used to describe this dependency relationship as illustrated in FIG. 5B, which becomes an effective descriptor for a scheduling strategy, with the maximum width of the DDT indicating the maximum parallel printing that can be achieved.

[0056] An exemplary embodiment of the present invention is illustrated in FIGS. 5A-5H. As shown, robots 500-503 are scheduled to print a rectangular block 520, which is divided into 20 chunks 0-19. As shown in FIG. 5C, Robots 502 and 503 print the center row by printing sections 0 and 1. Sections 0 and 1 a spaced distance apart or staggered so as to leave a gap between the sections so as to avoid any interference between robots 502 and 503 while printing. In a similar manner, as shown in FIG. 5D, sections 2 and 3, which are also staggered to space the robots apart, our next printed in accordance with the decision tree shown in FIG. 5B. FIG. 5E shows that once sufficient spacing between robots 500-503 is achieved so as to avoid collisions, all for robots can commence printing sections 4, 5, 12, and 13 in accordance with the decision tree shown in FIG. 5B. Again, as shown the sections are spaced apart so as to avoid interference. FIG. 5F shows the next sequence wherein sections 6, 7, 14 and 15 are printed by all for robots in accordance with the decision tree shown in FIG. 5B. FIG. 5G, in accordance with the decision tree shown in FIG. 5B, illustrates the printing of chunks 8, 9, 16 and 17. FIG. 5H, in accordance with the decision tree shown in FIG. 5B, illustrates the printing of chunks 10, 11, 18 and 19.

[0057] In a preferred embodiment, the objective of chunking is to divide the printing job into chunks such that they can be assigned to as many robots as possible to increase the printing speed. Therefore, the overall chunking strategy is highly dependent on the geometry of the print, the number of available robots and how the robots will be scheduled. To simplify the problem, an exemplary embodiment will be disclosed below for operation using two robots with applicability to larger scaling deploying many robots.

[0058] The methodology for splitting a print job into chunks for two robots will generally be applicable for many robots through a “divide and conquer” strategy which split the object into multiple chunks along one consistent direction. In a preferred embodiment, as shown in FIG. 6, object 600 may be chunked or sliced in the Y direction with opposingly located sloped planes 610 and 615 to ensure good bonding between chunks. Two robots start from the center chunk and print along 1Y and −Y direction, respectively, to finish each chunk. To calculate the geometries of these chunks, the original geometry of object 600 is bisected bisect multiple times around multiple planes. Because the problem to chunking was constrained only in the 1Y and −Y directions, each plane can be defined by two things: its slope and Y position.

[0059] A maximum slope angle will maximize the volume of each chunk and increase printing efficiency, especially as the sloped surface approaches 90-degrees or vertical. A minimum slope angle will maximize the area of the bonding interface and increase the bonding strength. Moreover, if the angle is very large or very small, either the front wheels of the robot or the nozzle will interfere with the printed material. It should be noted that the range of the angle is dependent on the printer design and the limits can be easily mitigated or eliminated with more degrees of freedom (DOF) of the robotic arm (e.g., one additional DOF to change the nozzle angle).

[0060] FIGS. 7A-D show an iterative chunking, for an embodiment of the present invention, where planes L and R are reused and shifted to split further chunks on the left and right of the center chunk 700. FIG. 7A shows a center chunk 700 that may be trapezoidal or triangular in shape with sloped sides 710 and 711 as well as top 712 and base 713. Top 712 is smaller than base 713.

[0061] FIG. 7B shows chunk 720 shifted plane R to the right by one chunk, FIG. 7C shows shifted plane R for subsequent chunks 730, 740, and 750. FIG. 7D shows shifted plane L for all left chunks 760, 770, 780, 790, and 800.

[0062] The dependency relationship between chunks is dependent on both chunk geometry and how the chunks are generated. For example, for two neighboring chunks, one chunk must have a positive slope angle (i.e., like a normal trapezoid) and be printed first, and the other one must have a negative slope angle (i.e., like an inverted trapezoid) and be printed last. As shown for chunk 720, it has a negative slope side 721 and a positive slope side 722. Negative slope side 721 mates with positive slope side 710 of center chunk 700.

[0063] The chunks do not need post-assembly as the next chunk is directly printed on top of the previous chunk, which will automatically bond together in a similar fashion to how the layers bonded together in the 3D printing process. (It can be thought as the previous layer (the printed chunk) is tilted an angle and the next layer (the next chunk) is printed on top of that.

[0064] In other embodiments of the present invention, the chunks can also be slightly overlapped to improve bonding strength as illustrated in FIGS. 8A-8C. If the chunks are printed exactly along the chunking plane, the overlapping is zero. A positive overlapping means more materials are squeezed into the chunking plane and will make the contact area between chunks denser. A negative overlapping indicates the chunks are not in contact with one another. FIG. 8A shows no overlap by fill 850 between edge 805 of chunk 810 and edge 820 of chunk 830. FIGS. 8B and 8C show fill 850 overlapping chunk 810 when chunk 830 is printed and completed.

[0065] While the foregoing written description enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The disclosure should therefore not be limited by the above-described embodiments, methods, and examples, but by all embodiments and methods within the scope and spirit of the disclosure.